Cosmetic sponge and method for providing a cosmetic sponge

ABSTRACT

This invention relates to a cosmetic sponge and a method of providing a cosmetic sponge incorporating a non-denatured collagen and other additives for skin care, cleaning, and cosmetic application.

CROSS REFERENCE TO CO-PENDING APPLICATIONS

This application is a continuation of and claims priority to U.S.application Ser. No. 15/189,184, filed on Jun. 22, 2016 and titled“Cosmetic Sponge and Method for Providing a Cosmetic Sponge,” which is adivisional of and claims priority to U.S. application Ser. No.13/633,605 filed on Oct. 2, 2012 and titled “Cosmetic Sponge and Methodfor Providing a Cosmetic Sponge,” which is a continuation of and claimspriority to U.S. application Ser. No. 13/176,841 filed on Jul. 6, 2011and titled “Footbed with Non-Denatured Collagen.” The contents of theseabove-referenced applications are relied upon and are incorporatedherein by reference in their entireties.

FIELD OF INVENTION

The invention relates to a cosmetic sponge, and more particularly to apolymer foam sponge containing a non-denatured collagen.

BACKGROUND OF INVENTION

Collagen is a general term describing a variety of naturally occurringproteins found in animals, especially in the flesh and connectivetissues. It is considered to be the most abundant protein in mammals,comprising 25% to 35% of the whole body protein.

The most abundant form of collagen is believed to be Type I collagen,which is found in skin, tendons, vascular ligature, organ, and bones.Type I collagen appears to comprise over 90% of the total collagen inthe body. The commonly accepted model characterizes type I collagen as afibrillar form of collagen, composed of three polypeptide strands in atriple helix. The triple helices are further associated into coiledcoils, which are associated further into super coils referred to ascollagen microfibrils. These microfibrils are interdigitated with othermicrofibrils, forming collagen fibrils which can be so well ordered asto be crystalline in some respects.

Isolated collagen has many uses, and a wide variety of techniques havebeen developed to isolate the collagen. These techniques can have verydifferent effects on the structure of the collagen, and on the formwhich is isolated. Treatment with strong acids and bases can hydrolyzethe cross-links and other intermolecular structures which hold thepolypeptide strands to each other, generating the viscous, water-solubleform of collagen known as gelatin. Cioca et al appears to teachtreatment with enzymes such as casein to isolate forms of collagen forthe manufacture of artificial chamois (Cioca et al, U.S. Pat. No.4,327,195, 1982). Acid extraction of calf tendons has been proposed toprepare a biocompatible fluid containing acid-soluble collagen forinjection. (Kemp et al, U.S. Pat. No. 5,106,949, 1992). Thesepreparations of soluble collagens would be expected to denature thecollagen, resulting in the disruption of the intermolecular bonding andof the fibril and microfibril structure of the collagen.

Insoluble forms of collagen I are typically produced by mechanicalmethods which avoid disruption of the intermolecular collagen bonding.One method proposed is a combination of simple cutting and grindingprocesses (eg Aceto et al, U.S. Pat. No. 3,665,998, 1972), and theresulting particulate collagen may be formed into structures by, forexample, suspension and freeze-drying (eg Cioca, U.S. Pat. No.4,412,947, 1983).

When refined to a small enough particle size, it has been reported thatthe natural structure of even “insoluble” collagen may be reduced to thepoint that it exhibits some solubility in strong solvents such asdimethyl sulfoxide and dimethyl formamide. In many cases, thesematerials can also be handled in water dispersions. The use of verysmall particles of lower molecular weight collagens (less than 0.5millimeter particles for molecular weights less than 30,000, forexample) has been reported to improve the properties of hydrophobicpolyurethane foams when used as a filler material. (Cioca et al, U.S.Pat. No. 4,327,195, 1985). Processing of the collagen to the extentrequired for this type of handling, however, may denature it to thepoint that the natural elasticity, flexibility, strength and stabilityof the collagen fibers is reduced.

In light of the number of techniques for processing collagen whichdenature the protein, the advantages of a clean, non-denatured collagenin combination with a polymer foam have yet to be realized. There isstill a need, therefore, for a sponge that incorporates non-denaturedcollagen fibers.

Collagen has been used in cosmetics applications both intradermally (byinjection) and extradermally (by application to the surface of theskin). Reportedly, one of the mechanisms of the visible appearance ofskin aging is the loss of collagen, resulting in a reduction of the softtissue and formation of wrinkles. Injectable collagen compositions (egJanzen et al, U.S. Pat. No. 5,523,291, 1996) have been proposed for softtissue augmentation, to reduce visible wrinkling in aging skin or toreduce the appearance of scarring, and to augment features such as lipsand cheeks. Cosmetic creams may contain hydrolyzed collagen for use asmoisturizers or to reduce the visible appearance of wrinkles and lines.Other skin treatments, including pastes and foils (eg Braumer et al,U.S. Pat. No. 4,131,650, 1978) may include soluble collagen in a formwhich can be transported to and absorbed by the skin. The lack of afibrillar structure in these hydrolyzed collagen products, however,typically results in reabsorption of the collagen into the body anddestruction by collagenase, requiring frequent reapplication of thetreatments.

There is also a need, therefore, for a non-hydrolyzed, non-denaturedcollagen which can be applied extradermally, and for a convenient formin which to apply that material.

What is desired is a cosmetic sponge and a method for providing acosmetic sponge that benefits from the properties imparted from theincorporation of a non-denatured collagen, and for a cosmetic spongethat can apply a beneficial form of non-denatured collagen to the skin.

SUMMARY OF INVENTION

It is therefore an object of the invention to provide a cosmetic spongecontaining a non-denatured collagen. In one embodiment, this cosmeticsponge comprises a polymer foam, non-denatured collagen, and at leastone additive. In one embodiment, this non-denatured collagen is formedby carefully controlling the pH and amount of heat to which the collagenis exposed during the extraction process. By avoiding extremes of pH andheat, the denaturation, or loss of natural structure, of the collagen isavoided or at least minimized. In one embodiment, the non-denaturedcollagen is prepared under pH conditions ranging from approximately 13to approximately 3. In another embodiment, the non-denatured collagen isprepared under pH conditions ranging from approximately 10 toapproximately 4. In yet another embodiment the non-denatured collagen isprepared under pH conditions ranging from approximately 8 toapproximately 5. In one embodiment, the non-denatured collagen has afiber length of less than approximately 10 mm.

In some embodiments, the additives are selected from a group consistingof: skin care agents, hydrocolloid absorptive agents, medicaments,proteins, enzymes, nucleic acids, vitamins, soaps, hemostatic agents,antibacterial agents, antifungal agents, surfactants, pH buffers,mineral salts, trace elements, plant extracts, animal extracts,disinfecting and sterilizing agents, and combinations thereof.

In some embodiments, the cosmetic sponge further comprises asuperabsorbent polymer.

In some embodiments, the invention comprises the reaction product of amixture containing a predetermined amount of non-denatured collagen, apredetermined amount of a prepolymer, and at least one additive. In oneembodiment, the additive or additives are selected from the groupconsisting of skin care agents, hydrocolloid absorptive agents,medicaments, proteins, enzymes, nucleic acids, vitamins, soaps,hemostatic agents, antibacterial agents, antifungal agents, surfactants,pH buffers, mineral salts, trace elements, plant extracts, animalextracts, disinfecting and sterilizing agents, and combinations thereof.In one embodiment, the mixture also contains a superabsorbent polymer.

A second object of the invention is to provide a method for making acosmetic sponge. In some embodiments, this method comprises the stepsof: forming a mixture having at least a predetermined amount ofnon-denatured collagen and water, and mixing a predetermined amount of aprepolymer with said mixture to form a foam layer. In some embodiments,the method further comprises the steps of adding an agent from the groupconsisting of a cross-linking agent, a catalyst, a surfactant, orcombinations thereof. In some embodiments, the method further comprisesthe step of adding at least one additive from the group consisting ofskin care agents, hydrocolloid absorptive agents, medicaments, proteins,enzymes, nucleic acids, vitamins, soaps, hemostatic agents,antibacterial agents, antifungal agents, surfactants, pH buffers,mineral salts, trace elements, plant extracts, animal extracts,disinfecting and sterilizing agents, and combinations thereof.

In some embodiments, the method further comprises the steps ofdepositing the mixture on releasable bottom paper disposed on a movablecarrier; covering the upper surface of the mixture with releasable toppaper as the aqueous mixture is moved with the movable carrier;advancing the foam layer in the top and bottom release paper by movingthe carrier; sizing the foam layer to the desired thickness; removingthe top and bottom releasable paper; and drying the sized cosmeticsponge to remove moisture.

A further object of the invention is to provide a layered compositematerial for use as a cosmetic sponge. In some embodiments, thismaterial comprises a cover layer and a foam layer, wherein the foamlayer is comprised of a polymer foam, a non-denatured collagen, and atleast one additive, and wherein a first surface of said foam layer is incontact with said cover layer. In one embodiment, the foam layer ishydrophilic with respect to said cover layer. In some embodiments, thecover layer comprises a material selected from the group consisting of arandomized polyester fiber material, a sock liner material, a non-wovenmaterial, a non-woven fiber web, and a felted non-woven fiber web. Insome embodiments the layered composite material comprises a third layerbonded to a second surface of said foam layer.

BRIEF DESCRIPTION OF FIGURES

The features of the invention believed to be novel and the elementscharacteristic of the invention are set forth with particularity in theclaims. The figures are for illustration purposes only and are not drawnto scale. The invention itself, however, both as to organization andmethod of operation, may be understood by reference to the detaileddescription which follows taken in conjunction with the accompanyingdrawings in which the drawings show typical embodiments of the inventionand are not intended to be limited of its scope.

FIG. 1 depicts one embodiment of a cosmetic sponge in accordance withthe present invention. FIG. 1a depicts the same embodiment in cutawayview, to show the internal structure of the sponge.

FIG. 2 is a flowchart depicting one embodiment of a method for providingthe cosmetic sponge shown in FIG. 1.

FIG. 3 is a flowchart depicting a second embodiment of a method forproviding the cosmetic sponge shown in FIG. 1.

FIG. 4 depicts an embodiment of the cosmetic sponge shown in FIG. 1 witha cover layer in accordance with the present invention. FIG. 4a depictsthe same embodiment in cutaway view, to show the internal structure ofthe sponge.

FIG. 5 depicts an embodiment of the cosmetic sponge shown in FIG. 1 witha cover layer and a third layer, in accordance with the presentinvention. FIG. 5a depicts the same embodiment in cutaway view, to showthe internal structure of the sponge.

DETAILED DESCRIPTION

FIGS. 1 and 1 a depict one embodiment of this invention, a cosmeticsponge comprising a polymer foam (1) containing a non-denatured collagen(2) and at least one additive (3) dispersed throughout. The nature andpreparation of the polymer foams in this invention reflect in part theteachings with regard to hydrophilic polyurethane foams of U.S. Pat.Nos. 5,976,616, 6,706,775, and 6,566,576, hereby incorporated byreference in their entirety.

In some embodiments of this invention, the polymer foam is prepared bypolymerization of an aqueous prepolymer mixture. In one embodiment, theaqueous prepolymer mixture comprises adequate water, a predeterminedamount of a hydrophilic urethane prepolymer, a predetermined amount ofnon-denatured collagen, and at least one additive. In some embodiments,the cosmetic sponge of the invention contains the reaction product of amixture comprising a predetermined amount of a non-denatured collagen, apredetermined amount of a prepolymer, and at least one additive.

In some embodiments, one or more additional components are added tomodify the properties of the resulting foam. In various embodiments,these components include dispersants to ensure that the at least oneadditive and the non-denatured collagen are adequately dispersedthroughout the foam; surfactants to modify the hydrophilicity of theresulting polymer foam, foaming and blowing agents to modify the number,size, and uniformity of the cells in the resulting foam. Othercomponents which are present in certain embodiments include one or morepolymer initiators, dyes, cross-linking agents, catalysts, orpolymer-chain size modifiers. In some embodiments, combinations ofadditional components are added to the prepolymer mixture. Thequantities and identities of such components can be readily determinedby one skilled in the art based on the desired properties of theresulting foam. Although certain prepolymers and structural features ofthe non-denatured collagens or additives listed below may in some casesalso act as polymer initiators, dyes, cross-linking agents, catalysts,or polymer-chain-size modifiers, for the purpose of this patent, thesecomponents when claimed separately are defined to be distinct from theprepolymers, additives, and non-denatured collagens present in themixtures.

In some embodiments of the invention, superabsorbent polymers are addedfor controlled release of the dispersed additives or the collagen or tomodify the water-absorbing or water-releasing properties of the foam.Suitable superabsorbent polymers and their characteristics can be foundfor example in U.S. Pat. Nos. 5,763,335 and 4,914,470, herebyincorporated by reference in their entirety. In general, superabsorbentsare considered to be water-insoluble materials which are capable ofabsorbing and retaining large amounts of water or other aqueous fluidsin relation to their own weight. In some industrial applications,compounds are considered to be superabsorbent when they can absorb atleast fifteen times their own weight of aqueous fluids.

The at least one additive in some embodiments of this invention isselected from a group consisting of skin care agents, hydrocolloidabsorptive agents, medicaments, proteins, enzymes, nucleic acids,vitamins, soaps, hemostatic agents, antibacterial agents, antifungalagents, surfactants, pH buffers, mineral salts, trace elements, plantextracts, animal extracts, disinfecting and sterilizing agents, andcombinations thereof.

The non-denatured collagen in some embodiments of this invention isprepared by a process which does not disrupt the fibrillar structure ofthe natural collagen. Without intending to be bound to a single theory,it can be noted that in general terms, the following description ofcollagen is widely accepted. Natural collagen is the most abundantprotein found in mammals, and is the main component of fibrousconnective tissue such as skin, tendons, and ligaments. There areseveral forms of collagen found in the body with differentmacromolecular structures, but over 90% of the collagen is a fibrousstructural form known as Type I collagen. This consists of protein chainsubunits with a relatively high proportion of glycine, proline, andhydroxyproline, each polypeptide strand forming a left-handed helix.Three of these subunits are twisted together to form a right-handedtriple helix “super-coil” stabilized by numerous hydrogen bonds. Thesetriple-helices further combine to form a right-handed “super-super-coil”called a collagen microfibril, which are further stabilized by thepresence of some covalent cross-linking. Multiple microfibrils associateto form tropocollagen, which is a fibril approximately 300 nm long and1.5 nm in diameter. These tropocollagens spontaneously self assembleinto larger fibrillar structures which are further stabilized byadditional covalent crosslinking between tropocollagen subunits. Stilllarger fibrillar bundles are formed with the aid of several differentclasses of proteins, glycoproteins, and proteoglycans to form insolublecollagen which composes different types of mature tissue.

Collagen can be isolated from these mature tissues by several processes,many of which denature the fibrillar structure of the collagen to agreater or lesser extent. Strong acids or bases and high temperaturesirreversibly hydrolyze the covalent bonding between peptide strands,leading to gelatin, or even further to degrade the protein strandsthemselves and yield a soup of amino acid residues. Strictly mechanicalprocesses can be used to isolate the collagen fibrils in a more or lesspure form from tissues such as calf tendon which contain less maturecollagen structures and relatively few contaminating proteins.

For the purposes of this application, a non-denatured collagen isdefined as natural collagen extracted from tissue by a process whichleaves the fibrillar bundles relatively intact but which substantiallyremoves extraneous tissues, fats, and proteins. Such collagen has notbeen solubilized by acidic or basic treatments and is largely insoluble.We have found that these non-denatured collagens have differentproperties from the denatured and solubilized collagen productsresulting from treatment with strong acids and bases, and are uniquelysuitable for several cosmetic sponge applications.

In some embodiments, this non-denatured collagen is formed by carefullycontrolling the pH and amount of heat to which the collagen is exposedduring the extraction process. By avoiding extremes of pH and heat, thedenaturation, or loss of natural structure, of the collagen is avoidedor at least minimized. One method for preparing a suitable collagen frombovine skin has been described in Brazilian patents PI09029915 andPI0203122, hereby incorporated by reference in their entirety. In theseprocesses, the skin from healthy cattle is treated to remove muscles andfat from the inner layer of the skin, and calcined with calciumhydroxide to allow the separation of the skin into an exodermis andendodermis. The endodermis is then treated with dilute acetic acid ordilute hydrochloric acid at only moderately low pH for de-calcination,pressed between sanitary rubber rollers in a drier to remove excesswater, then milled to form a slurry and dried with very short times in adrum dryer (120-170° C. for 30-45 seconds) or at lower temperatures in astatic bed (50-90° C. for 3 to 10 hours). Treatment by particle breaker,cutting mill, and hammer mill followed by hand-screening produce asubstantially sterile, uniform product having fiber lengths less than 10mm and advantageously between 3 and 5 mm, fat content less than 7%,moisture content less than 30%, and protein content between 70 and 95%.By maintaining a relatively narrow range of pH and relatively lowtemperatures, the collagen fibrils are denatured as little as possibleduring the isolation process. The upper limit of pH of the process ismaintained between approximately 8 and approximately 13, and the lowerlimit of pH is maintained between approximately 3 and approximately 5,more neutral pH being associated with less denaturization of theprotein. It has been found that this method of isolating collageninvolving a combination of chemical and mechanical processingcharacterized by careful control of pH and temperature not only providesa less denatured collagen product than previous chemical methods, withmore of the elasticity and structural characteristics of the naturalcollagen, but also provides a cleaner and purer product than theprevious mechanical processes.

We have found the properties of non-denatured collagen prepared underthese conditions to be uniquely suitable for use in the currentinvention. Collagen prepared under conditions in which the pH ismaintained between 3 and 13 forms fibers of suitable length, radius, andelasticity to be of benefit to the skin and to add firmness to theresulting sponge, while collagen formed under conditions in which thosepH ranges are exceeded loses most of its fibrous structure to form agelatinous, soluble material. In some embodiments, the collagen isprepared under still narrower pH conditions of between 4 and 10,resulting in thicker and stiffer collagen fibrils which contributeelasticity and still more firmness to the resulting sponge. In someembodiments, a stiffer, stronger collagen is prepared using conditionsof pH between 5 and 9, and the resulting sponge is also stronger andstiffer without losing the resilience and elasticity of non-denaturedcollagen. Even this narrower pH range is sufficient to remove theundesired proteins, fats, and other biological substances which would bepresent in collagen treated only at neutral pH or by strictly mechanicalprocesses, while leaving the fibril structure of the natural collagenintact. These differing forms of non-denatured collagen can be mixedwith each other in appropriate proportions to modify the properties ofthe resulting sponge.

In some embodiments, the polymer foam is a hydrophilic urethane foam.Hydrophilic urethane prepolymers are available in the commercialmarketplace, for example, those sold under the trademark BIPOL 6 by MaceAdhesives and Coatings, under the trademark HYPOL by The Dow ChemicalCompany, or under the trademark PREPOL by Lendall ManufacturingIncorporated. General procedures for the preparation and formation ofsuch prepolymers can be found in Polyurethane's Chemistry and Technologyby J. H. Saunders and K. C. Frisch published by John Wiley & Sons, NewYork, N.Y., at Vol. XVI Part 2. High Polymer Series, “Foam systems”.Pages 7-26, and “Procedures for the Preparation of Polymers”, pages 26et. seq. Admixing an aqueous mixture with a predetermined amount of thehydrophilic urethane prepolymer initiates polymerization. The physicalcharacteristics of the resulting polymer foam, such as density andtensile strength, are controlled by the ratio of prepolymer in theaqueous mixture.

In some embodiments, one or more agents including cross-linking agents,catalysts, or surfactants are added to the mixture to further modify thephysical characteristics of the resulting polymer foam. Cross-linkingagents are small multifunctional compounds that, under the appropriatereaction conditions, form additional covalently bonded cross-linksbetween segments of the polymer. In some embodiments, these additionalcrosslinks increase the stiffness, strength, or toughness of theresulting foam. In some embodiments they are used to link the collagenor the additives to the matrix of the polymer foam through covalentbonds. In some embodiments they are used to add desirable functionalityto the resulting foam such as color, hydrophilicity, visible orultraviolet light resistance or sensitivity, and resistance to oxidativedegradation.

Catalysts are materials which are used to modify the reaction rate ofthe polymerization reaction. In some embodiments, they are added topromote the polymerization reaction under specific conditions of air,heat or light activation, allowing control of such variables as pot lifeand reaction temperature of the prepolymer mixture, and cell formation,number, and size in the resulting foam. Some catalysts suitable for usein polyurethane systems include those sold under the trademark BiCAT byShepherd Chemical Company and those sold under the trademarks DABCO andPOLYCAT by Air Products.

Surfactants are compounds which are added to increase the solubility ofother materials in the aqueous prepolymer mixture. In one embodiment, asurfactant is added as part of the aqueous collagen mixture. In anotherembodiment, a surfactant is added as part of an aqueous solution ofother agents or additives prepared before addition to the prepolymermixture. In some embodiments, the surfactants are present in amounts ofabout 0.5% to about 5% by weight of the aqueous mixture. A wide varietyof anionic, cationic, non-ionic, and zwitterionic surfactants arecommercially available, and the choice of surfactant can be readilydetermined by one skilled in the art based on the nature of thematerials to be dissolved. In some embodiments, surfactants are used tomodify the resulting polymer foam by controlling the number or size ofthe cells, and in some embodiments the incorporation of the surfactantin the polymer matrix is used to modify the hydrophilicity of theresulting foam.

FIG. 2 depicts another embodiment of this invention; a method forproviding a cosmetic sponge comprising the steps of forming a mixturehaving at least a predetermined amount of non-denatured collagen andwater (100), and mixing a predetermined amount of prepolymer with saidmixture (200), forming a prepolymer mixture which polymerizes to form afoam layer (300).

In some embodiments, the predetermined amount of prepolymer is chosenbased on the handling characteristics of the resulting prepolymermixture. In many embodiments, this amount ranges from about 10% byweight to about 50% by weight of the prepolymer mixture. In someembodiments, the predetermined amount of the non-denatured collagen ischosen based on the desired properties and expected use of the resultingfoam. In many embodiments, this amount ranges from between about 1% byweight to about 25% by weight of the mixture. In some embodiments, theinvention comprises the additional step of adding one or more agentsselected from a group consisting of a cross-linking agent, a catalyst, asurfactant, and combinations thereof (201). In different embodiments,these agents are incorporated into the mixture of non-denatured collagenand water, incorporated into the prepolymer, or added separately. Insome embodiments, the invention comprises the additional step of addingat least one additive from the group consisting of skin care agents,hydrocolloid absorptive agents, medicaments, proteins, enzymes, nucleicacids, vitamins, soaps, hemostatic agents, antibacterial agents,antifungal agents, surfactants, pH buffers, mineral salts, traceelements, plant extracts, animal extracts, disinfecting and sterilizingagents, and combinations thereof (202). The order of addition of thevarious components does not form a part of this invention, and can beselected or changed without exceeding the intended scope of theinvention by those skilled in the art, based on considerations such asthe solubility of the components in the mixture, chemical stability, orease of manufacturing.

FIG. 3 depicts an embodiment of the present invention in which a methodis provided for forming a cosmetic sponge comprising the steps offorming an aqueous mixture having at least a predetermined amount ofnon-denatured collagen, a predetermined amount of prepolymer, and anadequate amount of water (1000); depositing the mixture on releasablebottom paper (2000); covering the upper surface of the mixture withreleasable top paper (3000); sizing the foam layer to the desiredthickness (4000); removing the top and bottom releasable paper (5000);and either simultaneously or subsequently drying the sized cosmeticsponge to remove moisture (6000). In some embodiments, the releasablebottom paper is disposed on a movable carrier. In some embodiments, thefoam layer, effectively contained between releasable papers, is advancedbetween steps of the process by moving the carrier. In some embodimentsthe cosmetic sponge is formed to the desired shape as it is sized(7000); in other embodiments, the sponge is formed as a separate stepeither before or after removing the releasable papers and drying thefoam.

In some embodiments of the invention, the cosmetic sponge is composed ofmore than one layer. Such layered composite materials reflect in partthe teachings of U.S. Pat. Nos. 5,763,335 and 6,025,287, which arehereby incorporated by reference in their entirety. FIGS. 4 and 4 adepict an embodiment of the present invention in which the cosmeticsponge is a layered composite material comprising a polymer foam (1)containing a non-denatured collagen (2) and at least one additive (3),in contact with a cover layer (4) of a second material. This contactbetween the polymer foam and the cover layer allows water and anyadditives present in the foam layer to be carried through into the coverlayer to the skin, and allows water and any solutes on the skin to becarried through the cover layer and into the underlying foam.

In some embodiments, the cosmetic sponge is covered by, and in someembodiments, bonded to, an additional layer of differing composition. Insome embodiments, a cover layer of material less hydrophilic than theunderlying polymer foam is provided. This allows water to be absorbed bythe polymer foam and water soluble additives to be released from thefoam and onto the cover layer, while leaving the cover layer dry enoughto act as an applicator for cosmetics or for the absorbed additives. Inother embodiments, a cover layer more hydrophilic than the underlyingpolymer foam is provided. This allows especially hydrophilic additivesto be more readily transferred to the cover layer for application. Inother embodiments, the cover layer has similar properties to theunderlying foam, differing in physical properties such as softness, poresize, or abrasiveness, to allow for two different surfaces of differingcharacteristics for applying cosmetics. In some embodiments, the coverlayer is similar to the underlying foam layer but includes a differentadditive or combination of additives.

In one embodiment, the cover layer is formed of randomized polyesterfiber material dispensed from a roll onto the upper surface of thepolymer foam. Randomized fiber materials are materials in which thefibers are not aligned throughout the material. In some embodiments, thefibers are aligned in two or more different directions in adjoiningportions of the material. In some embodiments, the fibers are aligned indifferent directions for different layers of the material. In someembodiments, the randomized fiber materials consist of non-oriented orrandomly oriented fiber materials, materials in which the fibers are notoriented in any particular direction and for which the direction of anyfiber within the material appears random.

The composite material is formed by joining the cover layer to thepolymer foam by any suitable means. In one embodiment, the foam andcover layer are joined by needle punching, which forces certain of thepolyester fibers into and sometimes through the foam to establish thecomposite material. When needle punching is used to connect the coverlayer to the foam layer, the fibers forming the cover layer are reducedto a generally non-measurable thickness, impart a fabric feel to the topsurface of the formed composite material, and act as a wick todistribute and transfer moisture or bodily fluids from the cover layerto the hydrophilic foam layer.

Other materials are used as cover layers to impart different propertiesto the composite foam material, and in different embodiments thematerial used as a cover layer is selected from randomized acrylic fibermaterial, sock liner material, thermoformable acrylic latex, non-wovenfiber web, or non-woven felted web materials. In different embodiments,the cover layer is attached to the foam by different means includingadhesives, radio frequency heating, flame bonding, or by directlypolymerizing the foam layer onto the cover layer.

FIGS. 5 and 5 a depict an embodiment of the present invention comprisinga polymer foam (1) containing a non-denatured collagen (2) and at leastone additive (3), a cover layer in contact with a first surface of saidfoam (4), and a third layer in contact with a second surface of saidfoam (5). In some embodiments the cover layer and third layer are bondedto the polymer foam; in other embodiments, the cover layer and thirdlayer are bonded together outside the periphery of the polymer foam,such that the cover layer and third layer together surround and enclosethe polymer foam. Like the cover layer, the third layer may be morehydrophilic, less hydrophilic, or of similar characteristics to theunderlying polymer foam, and in some embodiments contains the same, andin other embodiments contains different additives from the polymer foam.

In some embodiments, the cover layer, and if present the third layer,comprise a material selected from the group consisting of a randomizedpolyester fiber material, a sock liner material, a non-woven material, anon-woven fiber web, and a felted non-woven fiber web.

While the present invention has been particularly described, it isevident that many alternatives, modifications and variations will beapparent to those skilled in the art in light of the foregoingdescription. It is therefore contemplated that the appended claims willembrace any such alternatives, modifications, and variations as fallingwithin the true scope and spirit of the present invention.

What is claimed is:
 1. A method for providing a cosmetic spongecomprising the steps of: providing a non-denatured collagen with a fatcontent less than approximately 7%; forming an initial mixturecomprising said non-denatured collagen and water; mixing a prepolymerand at least one additive with said initial mixture to form a prepolymermixture; reacting said prepolymer mixture to form a resulting polymerfoam.
 2. The method of claim 1, further comprising the step of adding anagent from the group consisting of: a cross-linking agent, a catalyst, asurfactant, and combinations thereof.
 3. The method of claim 1, furthercomprising the step of adding at least one additive from the groupconsisting of skin care agents, hydrocolloid absorptive agents,medicaments, proteins, enzymes, nucleic acids, vitamins, soaps,hemostatic agents, antibacterial agents, antifungal agents, surfactants,pH buffers, mineral salts, trace elements, plant extracts, animalextracts, disinfecting and sterilizing agents, and combinations thereof.4. The method of claim 1, wherein the amount of said prepolymer used isbetween approximately 10% and approximately 50% by weight.
 5. The methodof claim 1, wherein the amount of said non-denatured collagen used isbetween approximately 1% and approximately 25% by weight.
 6. The methodof claim 1, further comprising said steps of: depositing said prepolymermixture on a releasable bottom paper disposed on a movable carrier;covering said upper surface of said prepolymer mixture with a releasabletop paper as said prepolymer mixture is moved with said movable carrier;advancing said prepolymer mixture in said top and bottom release paperby moving said carrier; sizing said resulting polymer foam to a desiredthickness to form a sized cosmetic sponge; removing said top and bottomreleasable paper; drying said sized cosmetic sponge to remove moisture.7. A method for providing a cosmetic sponge comprising the steps of:providing a non-denatured collagen with a protein content betweenapproximately 70% and approximately 95%; forming an initial mixturecomprising said non-denatured collagen and water; mixing a prepolymerand at least one additive with said initial mixture to form a prepolymermixture; reacting said prepolymer mixture to form a resulting polymerfoam.
 8. The method of claim 7, further comprising the step of adding anagent from the group consisting of: a cross-linking agent, a catalyst, asurfactant, and combinations thereof.
 9. The method of claim 7, furthercomprising the step of adding at least one additive from the groupconsisting of skin care agents, hydrocolloid absorptive agents,medicaments, proteins, enzymes, nucleic acids, vitamins, soaps,hemostatic agents, antibacterial agents, antifungal agents, surfactants,pH buffers, mineral salts, trace elements, plant extracts, animalextracts, disinfecting and sterilizing agents, and combinations thereof.10. The method of claim 7, wherein the amount of said prepolymer used isbetween approximately 10% and approximately 50% by weight.
 11. Themethod of claim 7, wherein the amount of said non-denatured collagenused is between approximately 1% and approximately 25% by weight. 12.The method of claim 7, further comprising said steps of: depositing saidprepolymer mixture on a releasable bottom paper disposed on a movablecarrier; covering said upper surface of said prepolymer mixture with areleasable top paper as said prepolymer mixture is moved with saidmovable carrier; advancing said prepolymer mixture in said top andbottom release paper by moving said carrier; sizing said resultingpolymer foam to a desired thickness to form a sized cosmetic sponge;removing said top and bottom releasable paper; drying said sizedcosmetic sponge to remove moisture.